Uniform lightweight concrete and plaster

ABSTRACT

Lightweight concrete and plaster are prepared by a novel method which assures that the aggregate is uniformly admixed with the cementitious material and other relatively heavy ingredients of the concrete and plaster mixes. This is accomplished by wetting the surfaces of the lightweight aggregate particles with an aqueous medium, admixing the wet aggregate particles with dry finely divided cementitious material to form a coating thereon, and thereafter adding additional aqueous medium in an amount to produce a coherent formable uncured concrete or plaster matrix. The uncured concrete or plaster matrix may be formed into a desired configuration, and then is allowed to set in the usual manner. The addition of hydrated lime improves the cohesive properties of an uncured concrete matrix. Increased strength in cured lightweight concrete may be obtained by admixing pozzolan, hydrated lime and/or finely divided inert inorganic fillers such as sand with the uncured concrete matrix. A lightweight aggregate including expanded polystyrene beads is preferred, and further increased strength may be obtained by using polystyrene beads expanded in hot water.

106-9 AU 115 EX United States Patent 1 91 1111 3,869,295

Bowles et a1. *Mar. 4, 1975 I UNIFORM LIGHTWEIGHT CONCRETE AND PLASTER Primary E.\'an1iner-Winston A. Douglas Assistant E.\-ami11erJohn P. Sheehan [76] lnvemors' gg f zl g' fi g i s f zggl Attorney, Agent. or FirmL. S. Van Landinghani. .lr.

Anchorage, Alaska 99501 1 Notice: The portion of the term of this [57] ABSTRACT patent subsequent to Oct. 9, 1990, has been disclaimed. We and master are prepared by a [22] Filed: Mar. 23. 1973 novel method which assures that the aggregate is uniformly admixed with the cementitious material and [21] Appl. No.: 344,431 other relatively heavy ingredients of the concrete and plaster mixes. This is accomplished by wetting the sur- A t D Roland U s pphca am faces of the 11ghtwe1ght aggregate particles with an [63] Continuation-impart of Ser. No. 24,022. March 30, aqueous medium A u I wet are ate articles 1970 with dry finely divided cementitigus material to grm a coating thereon, an thereafter adding additional 106/90 106/1 1 aqueous medium in an amount to produce a coherent [58] Field in H9 formable uncured concrete or plaster matrix. The uncured concrete or plaster matrix may be formed into a desired configuration, and then is allowed to set in the [56] References cued usual manner. The addition of hydrated lime improves UNITED STATES PATENTS the cohesive properties of an uncured concrete ma- Stastny [[iX Increased trength in cured on t 302mg M962 Th'essen 106/90 X may be obtained by admixing pozzolan, hydrated lime j and/or finely divided inert inorganic fillers such as ewn am e a. e 3.257.338 6/1966 Sefton 260/25 B "F concrete tt u u I exanded 01 st re u a 3.272.765 9/1966 Sefton e 3.503.771 3/1970 Kroyer PreferedJPd further 3.565.650 2/1971 Cordon mined y 3,764,357 10/1973 Bowles et a1 106/90 LEL- FOREIGN PATENTS OR APPLICATIONS 1.474.167 2/1967 France 264/D1G. 7

26 Claims, No Drawings UNIFORM LIGHTWEIGHT CONCRETE AND PLASTER RELATED APPLICATION This application is a continuation-in-part of our copending application Ser. No. 24,002 filed Mar. 30, 1970, now US. Pat. No. 3,764,357.

BACKGROUND OF THE INVENTION This invention broadly relates to the preparation, of lightweight concrete and plaster and, more specifically, to a novel method of admixing a uniform lightweight concrete or plaster wherein the aggregate is prevented from separating from cementitious material and other relatively heavy ingredients of the mix. The invention further relates to the improved lightweight concrete and plaster products prepared by the method of the invention.

The methods available heretofore for preparing lightweight concrete and plaster have not been entirely satisfactory. For example, the prior art has not provided a suitable method of admixing lightweight aggregates, which may weigh as little as one to two pounds per cubic foot, with cementitious materials and other heavy ingredients which may weigh as much as 100 pounds per cubic foot. As a result, when practicing the prior art methods, the lighter aggregate tends to separate from the relatively heavy ingredients including the cementitious material during the admixing step, and a uniform formable coherent uncured concrete or plaster matrix is not produced. There is also a tendency for a concrete matrix produced in accordance with prior art methods to undergo stratification when placed in a concrete form and upon curing, a uniform high strength lightweight concrete is not produced.

The present invention overcomes the abovementioned and other problems of the prior art. When practicing the present invention, the lightweight aggregate is admixed with the cementitious material under carefully controlled conditions which eliminate separation of the lightweight aggregate from heavier ingredients, and a coherent uncured concrete or plaster matrix is produced which may be formed and cured in accordance with prior art practices. The resultant lightweight concrete and plaster are further characterized by uniformity and high strength, and they have predictable weight and strength characteristics.

It is an object of the present invention to provide a novel method of preparing improved high strength lightweight concrete and plaster.

It is a further object to provide a novel method of preparing lightweight concrete and plaster wherein a lightweight aggregate, cementitious material, and other relatively heavy ingredients may be admixed with an aqueous medium under carefully controlled conditions to prepare a uniform coherent formable uncured concrete or plaster matrix which may be cured to produce high strength lightweight products.

It is still a further object to prepare improved high strength lightweight concrete and plaster from an aggregate including expanded polystyrene beads.

It is still a further object to provide a novel method of preparing high strength lightweight concrete and plaster from an aggregate including polystyrene beads expanded in hot water.

It is still a further object to provide the improved lightweight concrete and plaster products prepared by the method of the invention.

Still other objects and advantages of the inventionwill be apparent to those skilled in the art upon reference to the following detailed description and the examples.

DETAILED DESCRIPTION OF THE INVENTION INCLUDING PREFERRED VARIANTS THEREOF In accordance with one important variant of the present invention, lightweight concrete and plaster are prepared by wetifiim of particles of a lightweight aggregate with an aqueous medium. and then admixing the particles of wet aggregate with dry finely divided cementitious material to coat the particles therewith. The water contained initially in the wetted aggregate should be insufficient to produce a proper consistency in the uncured concrete matrix. Therefore. additional aqueous medium should be admixed with the coated aggregate particles in an amount to produce a cohesive formable uncured concrete matrix or plaster matrix having a desired consistency. Qthggingrgdignts Wetematduulastufifi w en e si ed. The resulting uncured concrete mai?ix or P lKWfl IiK..i.9!& i o. 229 of n ureqli t w h} fgngieor glasterchmdngatdesiredsanfi l tion,andisthen tion until i tjets. As will be discussed in greater detail hereinafter, there are certain preferred variants which produce improved results.

A wqutlia umthmw y be ployed in practicing the present invention. Examples of organic lightweight aggregates include expanded polyst rene bead 0th of ex anded s nthetic olymers, cork a er w t and wood fibre. Examples xpanded polystyrene beads are well known to the art, and may be prepared from small pellets or beads of polystyrene containing admixed therewith a heat activated expanding agent such as a volatile hydrocarbon. Examples of suitable hydrocarbons include n-pentane, isopentane and hexane. When the polystyrene particles are placed in dry steam, the polystyrene softens, the expanding agent volatilizes, and the vapor causes the particles to expand to many times their original size. The polystyrene softens and has to be cured for 24 hours before it can be handled, i.e., either for second stage expansion or use as aggregate. When expanded with steam, the expanded beads are carried in an airstream to a silo for curing as at this stage they are too soft to be handled. By varying the conditions, the particles may be expanded to about 20 60 times their original size, and are preferably expanded to approximately 40-50 times their original size. After the beads are expanded to the desired size, the expanding agent diffuses into the atmosphere and the beads are ready for use. Polystyrene beads for expansion are available from the manufacturer in 3 sizes and a denser mix is obtained by combining a mixture of sizes without increasing the weight.

The expanded polystyrene beads may vary substantially in particle size. As a general rule, the beads should be less than one-fourth inch in diameter, and preferably less than one-eighth inch. Enhanced strength in the cured concrete and plaster is often obtained with smaller bead sizes, and the beads may have diameters as small as 1/32-1/64 inch, for example. Beads having at Tyler Screen size of about 12-16 mesh are very satisfactory. The weight of the expanded polystyrene beads may vary substantially, but as a general rule is approximately 1-4 pounds per cubic foot. First stage expansion beads often have a weight of approximately 2 pounds per cubic foot, and second stage expansion beads approximately 1 pound per cubic foot.

In accordance with one presently preferred variant of the invention, the initial particles of polystyrene including the heat activated expanding agent are expanded by agitating in a body of hot water. The water is sufficiently hot to activate the expanding agent and may be, for example, about 2002l2F. Surprisingly, it has been discovered that the polystyrene beads thus produced may be used in preparing lightweight concrete and plaster which have greatly enhanced strength. For some reason which is not fully understood at the present time, expanding the polystyrene beads in hot water tends to strengthen the skins of the beads, and water or moisture seems to be entrapped within the expanded beads. The water content of the beads seems to be released gradually during the hydration, rehydration or crystallization of the cementitious material, and moisture is not withdrawn therefrom as is apparently true with polystyrene beads expanded in dry steam. Polystyrene beads expanded by dry steam are highly charged with static electricity, while, unexpectedly, polystyrene beads expanded in hot water are not. The size of the hot water-expanded polystyrene beads may be as given above for the steam-expanded polystyrene beads, but the weight per cubic foot may be somewhat higher. As a general rule, it is usually preferred that the hot waterexpanded polystyrene beads have a weight of about 3-4 pounds per cubic foot, and for best results about 3.5-3.6 pounds per cubic foot. The increased weight is largely due to the enhanced moisture content of the beads. Surprisingly, polystyrene beads expanded in hot water are hard and may be used as an aggregate immediately after removal from the hot water and without curing or other further treatment. If desired, the temperature ofthe water used in expanding the polystyrene beads may be above 212F., such as up to 220 230F., when a pressurized system is employed.

Any suitable hydraulic cement may be employed when preparing lightweight concrete in accordance with the present invention. Portland cement is preferred, and it may contain the usual additives. Special types of portland cements may be employed such as Portlandpozzolan cement, which is a Portland cement to which pozzolana is added during the grinding of the cement clinker. A Portland cement identified in the trade as high early strength Portland cement SS C-1 92, type 3, is especially useful when the lightweight aggregate is expanded polystyrene beads.

Prior art inorganic cementitious materials for plaster may be used when preparing lightweight plaster in accordance with the invention. Examples of suitable cementitious materials are disclosed in the text Manual of Lathing and Plastering," by John R. Diehl, A.I.A., and include calcined gypsum, hydrated lime, Portland cement and admixtures thereof. Calcined gypsum and- /or hydrated lime are usually preferred.

The amount of cementitious material to be used may vary over wide ranges and depends to some extent upon the desired strength ofil'i egiggdjjgllt lgighggoncr te or plasterandthe'iveight thereof. As a general rule, about 200-1,000 poundsoicementitious materi i s us ed pe gbic yardflofclighmeight aggregate, and prefeEbl y is about 600-800 pounds. However, it is understood that smaller or larger amounts may be used when desired.

The aqueous medium that is used to wet the particles of sssamnortaafu sdrxjnqrs nfisqif Fttttquslaeuaimmniaanuauaaeaw u limediym illiLliilflulixmthihufi l m ii iea.. d gat z.particlesmaybe.wate in q us emulsion of an organic binder forth; aggregate parti- C tgtt iauusit tsiw when employing an q ousemulsion of an organic polymeric binder, it is usually preferred that the particles of aggregate be wetted therewith, followed by coating the wetted aggregate particles with the inorganic cementitious material, and thereafter admixing water with the cement coated aggregate particles to provide the additional water for hydration, rehydration or crystallization required for hydration of the cementitious material, and to produce the desired formable cohesive concrete matrix or plaster matrix. The organic polymeric binder may be, for example, an aqueous emulsion or latex of polyvinyl chloride, copolymers of polyvinyl chloride with other ethylenically unsaturated monomers such as vinyl ace tate or vinyl alcohol, acrylic resins, polymides such as Nylon, e'rTcTiy'r'es ins and the like. Aqueous emulsions of organic polymers used in prior art water-based paints, such as, for example, Super Kem-Tone are suitable for use in practicing the present invention. The use of an aqueous medium which contains an organic polymeric binder in erfilsion form to wet the aggregate aids in 555112155 il fiieaefi hiere tiifiiiial zti fo rii jcfoiitr olled thickness of cementitious material to b c oated lhelfizOns it is also possible to use organic polymeric binders of this type in sub-zero weather. The heat of hydration has kept the matrix from freezing at +5F.

The present invention provides a convenient way of controlling the amount of inorganic cementitious material which is deposited in the coating on the aggregate particles, and assures that the particles are uniformly coated. It is possible, for example, to uniformly coat the particles with as little as 200 pounds of inorganic cementitious material per cubic yard oflightweight aggregate, and thereby produce an extremely lightweight concrete or plaster. While concrete and plaster containing 200 pounds of cementitious material per cubic yard have a relatively low strength as compared with concrete and plaster of the invention containing substantially more cementitious material, nevertheless the strength for a given weight and product is higher than may be produced in accordance with the prior art methods of mixing. This is also true of the heavier concretes and plasters of the invention which may contain up to about 1,000 pounds of cementitious material per cubic yard of aggregate.

In accordance with a further variant of the invention, it is possible and often desirable to build up a plurality of layers of cementitious material on the aggregate particles by repeating the steps of wetting and admixing dry cementitious material with the aggregate particles. For example, uncoated particles of light-weight aggregate may be wetted with the aqueous medium, followed by admixing with dry cementitious material in an amount to produce coated aggregate particles which are dry and free flowing, followed by wetting the individual cement coated particles with the aqueous medium a second time, and thereafter admixing the twicewetted aggregate particles with additional dry cementitious material. After the desired coating thickness has been reached, then the additional water that is needed for hydration, rehydration, or crystallization of the cementitious material and for producing a formable coherent uncured concrete matrix or plaster matrix may be admixed with the coated particles. Substantially any ratio of cementitious material to aggregate in the uncured concrete matrix or plaster matrix may be obtained by proceeding in the above manner.

In instances where the aggregate particles are subjected to a plurality of cement coating steps, it is helpful to include an aqueous emulsion of a polymeric binder in the aqueous medium that is used for wetting the particles. The polymeric binder aids in controlling the amount of water that is present on the aggregate particles. lt also aids in binding the particles together, improves coherence in the uncured matrix, and increases the strength of the final product.

When adding the additional aqueous medium of hydrating, rehydrating or crystallizing the cementitious material and providing the optimum consistency in the uncured concrete matrix or plaster matrix, it is usually preferred that controlled increments be added while the matrix is being mixed. This procedure assures that a uniform concentration of the aqueous medium is obtained throughout the matix.

The apparatus employed to admix the lightweight aggregate with the aqueous medium and the inorganic cementitious material preferably includes blade means for scouring the sides of the mixing vessel, and slicing into and folding the matrix inward toward the center of the mass that is being mixed with the least possible drag and subsequent entrapped air. An example of a mixing apparatus of this type is a pug mill with the blade being modified to slice into the matrix and to fold it toward the center mixer, but it is understood that other suitable apparatus operating on the above principle may be employed. The order of addition of the ingredients to the mixing vessel is also of importance. For best results, the lightweight aggregate is added to the mixing vessel, followed by sufficient aqueous medium to uniformly coat the surfaces of the particles with a thin film. After mixing the aqueous medium and aggregate for a sufficient period of time to uniformly wet the surfaces of the particles, the dry cementitious material is added and the mixing is continued until the particles are uniformly coated with cement. Usually about one to two minutes are required for mixing the cement with the wet aggregate, and approximately 1 minute is required for wetting the beads with the aqueous medium. The additional aqueous medium in an amount to hydrate, rehydrate, or crystallize the cement and provide the desired consistency in the matrix is then added, and the mixing is continued until a uniform uncured matrix is produced. Additional ingredients also may be added, and may be admixed in the uncured matrix as discussed hereinafter.

The lightweight concrete produced in accordance with the invention has increased strength in instances where pozzolan is included in the uncured concrete matrix. As used herein, the term pozzolan embraces those substances which are capable of reacting with the lime that is released during hydration of the hydraulic cement, and especially pulverulent siliceous or sili-.

ceous-aluminous materials that react chemically with slaked lime at ordinary temperatures in the presence of moisture to form a cementitious compound. Examples of naturally occurring pozzolan include volcanic ash or minerals derived from volcanic ash, and similar siliceous or siliceous-aluminous minerals. Examples of pozzolan that is produced synthetically include fly-ash and certain slags.

The pozzolan may be added at the time of manufacturing the hydraulic cement such as when a Portlandpozzolan cement is produced. Alternatively, finely divided pozzolan may be admixed with the hydraulic cement and the cement-pozzolan mixture used to coat the wet aggregate, or the pozzolan may be admixed with the concrete matrix following the hydraulic cement.

More than one lightweight aggregate may be included in the concrete matrix or plaster matrix. For example, a mixed aggregate may be wetted initially with the aqueous medium, and then admixed with the inorganic cementitious material. it is also possible to admix additional lightweight aggregates in the concrete matrix or plaster matrix after it is produced. For best results, when lightweight aggregate is admixed with the concrete matrix or plaster matrix, it should be added in an amount less than 50% by volume of that initially present.

Finely divided hydrated lime increases the cohesive properties of the concrete matrix, and also increases the strength of the cured concrete. The hydrated lime may be added in an amount up to about 15% by weight of the hydraulic cement, and for best results, about 5-10% by weight is added.

to the concrete matrix after making the final addition of the aqueous medium or concurrently therewith.

Inert finely divided fillers such as sand and finely crushed stone may be added to the concrete matrix or plaster matrix. The fillers increase the strength of the cured concrete or plaster, but the weight is also increased very substantially. Nevertheless, it is often possible to add the fillers in amounts up to about three times the weight of the cementitious material and produce concrete or plaster having greater strength per unit weight. For example, in some instances the strength of concrete may be tripled by making a controlled addition of inert filler to the concrete matrix after making the final water addition or concurrently therewith, and the weight is only doubled.

Q on ventional air entraining agents may be added to M22159. 2EBJZLEQHiuQLi mat l iiiQllqttifl8..2E9 art practic fFor instance, the air entraining agent may be added to the concrete matrix along with the aqueous medium, and then vigorously admixed therewith to assure that in final concrete product has numerous small internally arranged voids.

When practicing a presently preferred variant of the method of the invention for preparing concrete, the lightweight aggregate should be wetted with the aqueous medium, and thereafter the wet aggregate should be admixed with the dry hydraulic cement. It is understood that the hydraulic cement may contain other f nely divided ing ed i e n t s at tlit i m e that with the'w e ate. Fo

finely divided pozzolan, lime, and/or inert filler may be EQLNJLLLHQM raulicfilnfintcm ilhilfl if s P odu d m y be mixedwith. thewet a r ggt As a general rule, with the possible exception of pozzolan, this is not the preferred practice and only the hydraulic cement is admixed with the wet aggregate to produce the cement-coated aggregate particles. Thereafter, the additional aqueous medium may be added, and the hydrated lime, inert filler, and/or additional light aggregate are added concurrently with or following the additional aqueous medium. The various additions are preferably made with continuous agitation of the concrete matrix so as to assure uniform distribution thereof.

For some reason which is not fully understood at the present time, the additional aqueous medium may be added to the cement-coated aggregate particles in the amount defined herein without causing the same to separate from the matrix during the mixing step. Stratification is also prevented during the curing step. As a result, the lightweight concrete or plaster prepared in accordance with the invention has the maximum possible strength per unit weight that is achievable with a given ratio and weight of ingredients. Increased compressive strength may be obtained by carefully selecting and controlling the ingredients of the mix and the amounts thereof. The amount of water in the aqueous medium should be controlled within optimum limits for maximum compressive strength of concrete. It is usually preferred to admix the lightweight aggregate for concrete with only sufficient water to provide a thin uniform film thereon, followed by admixing the dry hydraulic cement with the wet aggregate, followed by a final addition of water in an amount of about 0.3-0.5, and preferably about 0.4, times the weight of the hydraulic cement. When preparing plaster, the initial water for wetting the aggregate is the same as when preparing concrete, and the final addition of water is usually in an amount of 0.35-0.60, and preferably 0.40-0.55, times the weight of the inorganic cementitious material. It is understood that any additional water that is needed to provide a desired consistency and to produce a coherent formable matrix may be added.

In many instances concrete products having t h e greatest compressive stren th per unit weight are prodfied from a concrete matrix containing the lightweighfaggregate, hydraufic cement, pozzolan and'nyrate me. nert fillers such as sand, crushed stone and additional lightweight aggregate also are added. The ratios of Portland cement, pozzolan and hydrated lime are of importance. The pozzolan should be present in an amount less than 30% by weight of the hydraulic cement and preferably in an amount of about 10-20% by weight. The hydrated lime should be present in an amount of about 5-l0% by weight of the hydraulic cement. Polystyrene beads expanded in hot water in com bination with hydraulic cement, pozzolan and hydrated lime within the foregoing ranges produces optimum results in most instances. With this combination of ingredients, it is possible to prepare structural grade lightweight concretes having compressive strengths greater than 1,000 pounds per square inch, and having weights of less than 60 pounds per cubic foot, and often less than 50 pounds per cubic foot. Polystyrene beads are also preferred for plaster as a constant amount of water is absorbed, and a uniform predictable final lightweight product is produced.

The formable uncured concrete matrix produced in accordance with the invention may be used in preparing diyerse products such as builcfing bl oclgs and brigks.

and fof other construction purposes such as walls road Beds, sidewalEs, and foundations The formable uncured plaster-13am of the invention may be used in preparing lightweight insulation board, and it also may be sprayed, cast and/or troweled onto surfaces in buildings and the like. The final products thus produced have a.unique combination of properties as they are noncombustible, chemically inert and noncorrosive. The products are also efficient insulators, and have relatively high strength per unit weight.

The foregoing detailed description and the following specific examples are for purposes of illustration only, and are not intended as being limiting to the spirit or scope of the appended claims. The AC1 method of proportions No. 613A is used herein for determining the proportions of ingredients in the concrete and plaster mixes.

EXAMPLE 1 This example illustrates the preparation of lightweight concrete when using first stage polystyrene beads expanded in dry steam as the lightweight aggregate. The expanded polystyrene beads weighed 2 pounds per cubic foot, and had diameters of approximately one-eighth inch to one-fourth inch.

The aqueous medium was water, and the hydraulic cement was an early strength Portland cement known in the art as SS-C-l92, type 3. The pozzolan, hydrated lime, sand and perlite were commercial grades conventionally used in the preparation of concrete. The air entraining agent was Derex.

Concrete mixes were prepared from the ingredients set out in Table 1 below employing a modified pug mill as the mixing apparatus. The blade of the pug mill was modified to slice into the matrix and to fold it toward the center mixer with the least possible drag and subsequent entrapped air. The order of addition and amounts of ingredients was as they appear from left to right in Table l. in general, the expanded polystyrene beads were placed in the mixer, and then the wetting water was added. The beads were mixed with the setting water for approximately 1 minute. At the end of this mixing period, the polystyrene beads were uniformly wetted with the water, and then the dry Portland cement was added and the mixing was continued for approximately 1 h minutes. The matrix turned a gray color upon admixing with the Portland cement, and the beads had a uniform film of Portland cement thereon at the end of the mixing period. The air entraining agent was added to the water of hydration, and the mixture of water and air entraining agent was added and admixed. The pozzolan was admixed with the Portland cement, and the Portland cement-pozzolan mixture was used in coating the wetted beads. The hydrated lime, sand and perlite were added in that order after addition of the water of hydration and admixed.

The concrete matrix for each run was placed in a test mold, cured for seven days, and tested for compressive strength which was recorded in pounds per square inch. The weight of the concrete was determined and recorded in pounds per cubic foot.

The data thus obtained appear in Table l.

TABLE 1 Test Polystyrene Water C e- Pozzolan Derex Hydrated Sand Perl ite Weight Compressive ment Beads (lbs) (lbs) (lbs) (Grams) Lime (lbs) (lbs) (lbs/fl) Strength (lbs) (p.s.1.) Cu. Wet- Hydra- Lbs. Ft. ting tion Total EXAMPLE 11 runs. in an addmonal run, the cement1tious material The general procedure of Example 1 was repeated with the exception of using polystyrene beads which had been expanded in hot water having a temperature of 200-212F. The hot water expanded polystyrene beads weighed 3.6 pounds per cubic foot, and apparently had some water entrapped within the beads. In general, the order of addition of ingredients was as in Example I, i.e., as they appear when reading from left to right in Table 11.

The data thus obtained appear in Table I1.

was a mixture of hydrated lime and calcined gypsum.

Plaster mixes were prepared from the ingredients listed in Table 111 employing modified pug mill as a mixing apparatus. The pug mill was modified as set out in Example 1. The order of addition and the amounts of ingredients was as they appear from left to right in Table 111.

In general, the expanded polystyrene beads were placed in the mixer, and wetting water was added. The beads were mixed with the wetting water for approximately 1 minute. At the end of this mixing period, the

TABLE 11 Test Polystyrene Water Cement Pozzolan Hydrated Weight Compressive Beads (lbs) (lbs) (lbs) Lime (lbs/f1) Strength (lbs) (p.s.1.) Lbs. Cu.Ft. Wetting Hydration Total 7 14 28 Day Day Day EXAMPLE 111 polystyrene beads were uniformly wetted with the water, and then the dry flnely divided calclned gypsum was added and the mixing was continued for approximately 1 1: minutes. At the end of the mixing period, the beads had a uniform coating of the gypsum thereon. The water of rehydration was added, and the mixing was continued until a uniform formable coherent plaster matrix was produced. In the one run where a mixture of calcined gypsum and hydrated lime was used as the cementitious material, the hydrated lime was added after the water of rehydration and admixed in the matrix.

The plaster matrix for each run was placed in a test mold, cured for 7 days. and tested for compressive strength which was recorded in pounds per square inch. The weight of the plaster was determined and recorded in pounds per cubic foot.

The data thus obtained appear in Table Ill.

1. In a method of preparing lightweight building material wherein a lightweight aggregate comprising expanded polystyrene beads is admixed with an aqueous medium and inorganic cementitious material in amounts to produce a coherent forrnable uncured lightweight matrix which sets upon standing,

said matrix is formed into a body of uncured lightweight self-setting building material having a desired configuration and said body is maintained in the desired configuration until it sets and the resulting set body is cured to form cured lightweight building material,

the improvement which comprises preparing the coherent forrnable uncured lightweight matrix from an aggregate consisting essentially of polystyrene beads expanded in hot water, the said polystyrene beads containing water from the expansion thereof in the hot water and the said water content causing the polystyrene beads to have a weight of at least 3 pounds per cubic foot. the polystyrene beads being admixed with the aqueous medium and inorganic cementitious material in the absence of an added homogenizing agent which aids in coating the polystyrene beads with the cementitious material, and the said body upon setting and curing being coherent and substantially free of cracks.

2. The method of claim 1 wherein polystyrene beads including a heat activated expanding agent are introduced into hot water and expanded therein,

the wet expanded polystyrene beads thus prepared are recovered from the hot water, and

the expanded polystyrene beads are admixed with the inorganic cementitious material while wet.

3. The method of claim 1 wherein the said coherent forrnable uncured lightweight matrix is prepared from an aggregate consisting of the said polystyrene beads expanded in hot water.

4. in a method of preparing lightweight concrete wherein a lightweight aggregate comprising expanded polystyrene beads is admixed with an aqueous medium TABLE 111 Test Polystyrene Water Calcined Hydrated Weight Compressive Beads (lbs) Gypsum Lime (lbs/ft) Strength (lbs) (lbs) (psi) Lbs. Cu.Ft Wetting Rehydration Total 7 D We claim: form cured lightweight concrete,

the improvement which comprises preparing the lightweight concrete from an aggregate consisting essentially of polystyrene beads expanded in hot water, the said polystyrene beads containing water from the expansion thereof in the hot water and the said water content causing the polystyrene beads to have a weight of at least 3 pounds per cubic foot, the polystyrene beads being admixed with the aqueous medium and the hydraulic cement in the absence of an added homogenizing agent which aids in coating the polystyrene beads with the hydraulic cement, and the said body upon setting and curing being coherent and substantially free of cracks.

5. The method of claim 4 wherein polystyrene beads including a heat activated expanding agent are introduced into hot water and expanded therein,

the wet expanded polystyrene beads thus prepared are recovered from the hot water, and

the expanded polystyrene beads are admixed with the hydraulic cement while wet.

6. The method of claim 4 wherein the said lightweight concrete is prepared from an aggregate consisting of the said polystyrene beads expanded in hot water. .7 H g H 7. The method of claim 4 wherein the uncured concrete matrix also contains admixed therewith up to about 30% by weight of finely divided pozzolan based upon theweight of the hydraulic cement 8. The method of claim 4 wherein the uncured concrete matrix also contains admixed therewith up to about 15% by weight of finely divided hydrated lime based upon the weight of the hydraulic cement.

9. The method of claim 4 wherein the uncured concrete matrix also contains admixed therewith a finely divided inert inorganic filler in an amount up to about threem ius sh fm-h rau1i em nt- 10. The method of claim 4 wherein the uncured concrete matrix also contains admixed therewith an effective amount of an air entraining agent.

11. The method of claim 4 wherein the aqueous medium comprises an aqueous suspension of an organic polymeric binder for the lightweight aggregate.

12. The method of claim 4 wherein the uncured concrete matrix also contains admixed therewith at least one additional lightweight aggregate.

13. The method of claim 12 wherein the additional lightweight aggregate is perlite.

14. The method of claim 4 wherein the uncured concrete matrix also contains admixed therewith up to about 30% by weight of finely divided pozzolan and up to about 15% by weight of finely divided hydrated lime based upon the weight of the hydraulic cement.

15. The method of claim 4 wherein the uncured concrete matrix also contains admixed therewith up to about 30% by weight of finely divided pozzolan based upon the weight of the hydraulic cement and a finely divided inert inorganic filler in an amount up to about three times the weight of the hydraulic cement.

16. The method of claim 4 wherein the uncured concrete matrix also contains admixed therewith a finely divided inert inorganic filler in an amount up to about three times the weight of the hydraulic cement and finely divided hydrated lime in an amount up to about 15% by weight of the hydraulic cement.

17. The method of claim 4 wherein the uncured concrete matrix also contains admixed therewith up to about by weight of finely divided pozzolan based upon the weight of the hydraulic cement, sand in an amount up to about three times the weight of the hydraulic cement, and finely divided hydrated lime in an amount up to about 15% by weight of the hydraulic cement.

18. In a method wherein a lightweight aggregate comprising expanded polystyrene beads is admixed with an aqueous medium and inorganic cementitious material for plaster in amounts to produce a coherent formable uncured lightweight plaster matrix which sets upon standin said plaster matrix is formed into a body of uncured lightweight plaster having a desired configuration, and said body is maintained in the desired configuration until it sets and the resulting set body is cured to form cured lightweight plaster,

of preparing lightweight plaster the improvement which comprises preparing the lightweight plaster from an aggregate consisting essentially of polystyrene beads expanded in hot water, the said polystyrene beads containing water from the expansion thereof in the hot water and the said water content causing the polystyrene beads to have a weight of at least 3 pounds per cubic foot. the polystyrene beads being admixed with the aqueous medium and the inorganic cementitious material for plaster in the absence of an added homogenizing agent which aids in coating the polystyrene beads with the said inorganic cementitious material, and the said body upon setting and curing being coherent and substantially free of cracks.

19. The method of claim 18 wherein polystyrene beads including a heat activated expanding agent are introduced into hot water and expanded therein,

the wet expanded polystyrene beads thus prepared are recovered from the hot water, and

the expanded polystyrene beads are admixed with the cementitious material while wet.

20. The method of claim 18 wherein the said lightweight plaster is prepared from an aggregate consisting of the said polystyrene beads expanded in hot water.

21. The method of claim 18 wherein the cementitious material is selected from the group consisting of calcined gypsum, hydrated lime, Portland cement and admixtures thereof.

22. The method of claim 18 wherein the uncured plaster matrix also contains admixed therewith a finely divided inert inorganic filler in an amount up to about three times the weight of the cementitious material.

23. The method of claim 18 wherein the aqueous medium comprises an aqueous suspension of an organic polymeric binder for the lightweight aggregate.

24. The method of claim 18 wherein the uncured plaster matrix also contains admixed therewith at least one additional lightweight aggregate.

25. The method of claim 18 wherein the cementitious material comprises calcined gypsum.

26. The method of claim 18 wherein the cementitious material comprises hydrated lime.

k i 4 III 

1. IN A METHOD OF PREPARING LIGHTWEIGHT BUILDING MATERIAL WHEREIN A LIGHTWEIGHT AGGREGATE COMPRISING EXPANDED POLYSTYRENE BEADS IS ADMIXED WITH AN AQUEOUS MEDIUM AND INORGANIC CEMENTITIOUS MATERIAL IN AMOUNTS TO PRODUCE A COHERENT FORMABLE UNCURED LIGHTWEIGHT MATRIX WHICH SETS UPON STANDING, SAID MATRIX IS FORMED INTO A BODY OF UNCURED LIGHTWEIGHT SELF-SETTING BUILDING MATERIAL HAVING A DESIRED CONFIGURATION AND SAID BODY IS MAINTAINED IN THE DESIRED CONFIGURATION UNTIL IT SETS AND THE RESULTING SET BODY IS CURED TO FORM CURED LIGHTWEIGHT BUILDING MATERIAL, THE IMPROVEMENT WHICH COMPRISES PREPARING THE COHERENT FORMABLE UNCURED LIGHTWEIGHT MATRIX FROM AN AGGREGATE CONSISTING ESSENTIALLY OF POLYSTYRENE BEADS EXPANDED IN HOT WATER, THE SAID POLYSTYRENE BEADS CONTAINING WATER FROM THE EXPANSION THEREOF IN THE HOT WATER AND THE SAID WATER CONTENT CAUSING THE POLYSTYRENE BEADS TO HAVE A WEIGHT OF AT LEAST 3 POUNDS PER CUBIC FOOT, THE POLYSTYRENE BEADS BEING ADMIXED WITH THE AQUEOUS MEDIUM AND INORGANIC CEMENTITIOUS MATERIAL IN THE ABSENCE OF AN ADDED HOMOGENIZING AGENT WHICH AIDS IN COATING THE POLYSTYRENE BEADS WITH THE CEMENTITIOUS MATERIAL, AND THE SAID BODY UPON SETTING AND CURING BEING COHERENT AND SUBSTANTIALLY FREE OF CRACKS.
 2. The method of claim 1 wherein polystyrene beads including a heat activated expanding agent are introduced into hot water and expanded therein, the wet expanded polystyrene beads thus prepared are recovered from the hot water, and the expanded polystyrene beads are admixed with the inorganic cementitious material while wet.
 3. The method of claim 1 wherein the said coherent formable uncured lightweight matrix is prepared from an aggregate consisting of the said polystyrene beads expanded in hot water.
 4. In a method of preparing lightweight concrete wherein a lightweight aggregate comprising expanded polystyrene beads is admixed with an aqueous medium and hydraulic cement in amounts to produce a coherent formable uncured lightweight concrete matrix which sets upon standing, said concrete matrix is formed into a body of uncured lightweight concrete having a desired configuration, and said body is maintained in the desired configuration until it sets and the resulting set body is cured to form cured lightweight concrete, the improvement which comprises preparing the lightweight concrete from an aggregate consisting essentially of polystyrene beads expanded in hot water, the said polystyrene beads containing water from the expansion thereof in the hot water and the said water content causing the polystyrene beads to have a weight of at least 3 pounds per cubic foot, the polystyrene beads being admixed with the aqueous medium and the hydraulic cement in the absence of an added homogenizing agent which aids in coating the polystyrene beads with the hydraulic cement, and the said body upon setting and curing being coherent and substantially free of cracks.
 5. The method of claim 4 wherein polystyrene beads including a heat activated expanding agent are introduced into hot water and Expanded therein, the wet expanded polystyrene beads thus prepared are recovered from the hot water, and the expanded polystyrene beads are admixed with the hydraulic cement while wet.
 6. The method of claim 4 wherein the said lightweight concrete is prepared from an aggregate consisting of the said polystyrene beads expanded in hot water.
 7. The method of claim 4 wherein the uncured concrete matrix also contains admixed therewith up to about 30% by weight of finely divided pozzolan based upon the weight of the hydraulic cement.
 8. The method of claim 4 wherein the uncured concrete matrix also contains admixed therewith up to about 15% by weight of finely divided hydrated lime based upon the weight of the hydraulic cement.
 9. The method of claim 4 wherein the uncured concrete matrix also contains admixed therewith a finely divided inert inorganic filler in an amount up to about three times the weight of the hydraulic cement.
 10. The method of claim 4 wherein the uncured concrete matrix also contains admixed therewith an effective amount of an air entraining agent.
 11. The method of claim 4 wherein the aqueous medium comprises an aqueous suspension of an organic polymeric binder for the lightweight aggregate.
 12. The method of claim 4 wherein the uncured concrete matrix also contains admixed therewith at least one additional lightweight aggregate.
 13. The method of claim 12 wherein the additional lightweight aggregate is perlite.
 14. The method of claim 4 wherein the uncured concrete matrix also contains admixed therewith up to about 30% by weight of finely divided pozzolan and up to about 15% by weight of finely divided hydrated lime based upon the weight of the hydraulic cement.
 15. The method of claim 4 wherein the uncured concrete matrix also contains admixed therewith up to about 30% by weight of finely divided pozzolan based upon the weight of the hydraulic cement and a finely divided inert inorganic filler in an amount up to about three times the weight of the hydraulic cement.
 16. The method of claim 4 wherein the uncured concrete matrix also contains admixed therewith a finely divided inert inorganic filler in an amount up to about three times the weight of the hydraulic cement and finely divided hydrated lime in an amount up to about 15% by weight of the hydraulic cement.
 17. The method of claim 4 wherein the uncured concrete matrix also contains admixed therewith up to about 30% by weight of finely divided pozzolan based upon the weight of the hydraulic cement, sand in an amount up to about three times the weight of the hydraulic cement, and finely divided hydrated lime in an amount up to about 15% by weight of the hydraulic cement.
 18. In a method of preparing lightweight plaster wherein a lightweight aggregate comprising expanded polystyrene beads is admixed with an aqueous medium and inorganic cementitious material for plaster in amounts to produce a coherent formable uncured lightweight plaster matrix which sets upon standing, said plaster matrix is formed into a body of uncured lightweight plaster having a desired configuration, and said body is maintained in the desired configuration until it sets and the resulting set body is cured to form cured lightweight plaster, the improvement which comprises preparing the lightweight plaster from an aggregate consisting essentially of polystyrene beads expanded in hot water, the said polystyrene beads containing water from the expansion thereof in the hot water and the said water content causing the polystyrene beads to have a weight of at least 3 pounds per cubic foot, the polystyrene beads being admixed with the aqueous medium and the inorganic cementitious material for plaster in the absence of an added homogenizing agent which aids in coating the polystyrene beads with the said inorganic cementitious material, and the said body upon setting and curing being coherent and subStantially free of cracks.
 19. The method of claim 18 wherein polystyrene beads including a heat activated expanding agent are introduced into hot water and expanded therein, the wet expanded polystyrene beads thus prepared are recovered from the hot water, and the expanded polystyrene beads are admixed with the cementitious material while wet.
 20. The method of claim 18 wherein the said lightweight plaster is prepared from an aggregate consisting of the said polystyrene beads expanded in hot water.
 21. The method of claim 18 wherein the cementitious material is selected from the group consisting of calcined gypsum, hydrated lime, Portland cement and admixtures thereof.
 22. The method of claim 18 wherein the uncured plaster matrix also contains admixed therewith a finely divided inert inorganic filler in an amount up to about three times the weight of the cementitious material.
 23. The method of claim 18 wherein the aqueous medium comprises an aqueous suspension of an organic polymeric binder for the lightweight aggregate.
 24. The method of claim 18 wherein the uncured plaster matrix also contains admixed therewith at least one additional lightweight aggregate.
 25. The method of claim 18 wherein the cementitious material comprises calcined gypsum.
 26. The method of claim 18 wherein the cementitious material comprises hydrated lime. 